System and method for automated control, feed, delivery verification, and inventory management of corrosion and scale treatment products for water systems

Abstract

A system and method of controlling the treatment of water systems comprises multiple feeders for separately feeding treatment products, in the form of concentrated, non-hazardous, liquids with a single active ingredient, to a water system to treat various issues, such as corrosion and biofilms. A sensor verifies delivery of the treatment product to the water system. A controller controls activation of each feeder to control a feed rate according to programmed functions. The controller receives signals from sensors, which can be used as inputs in calculating feed rates or feeder activation times according to the programed functions and can alter treatment product feed rates based on real time data regarding water system chemistry or flow rates. The controller can send and receive data, signals, alerts, alarms or changes in programming to or from remote users, remote computers, or a water system controller.

We claim: 
     
       1. A method of controlling treatment of a water system comprising water, the method comprising the steps of:
 providing two or more containers, each containing an initial volume of one of a plurality of treatment products; 
 wherein each container is connectable to a feeder using one or more connection components to feed the treatment product from that container to the water system and; 
 providing a controller configured to send signals to the feeders and to receive data or signals from one or more optional sensors located upstream or downstream of the feeders, the controller having a plurality of programmed functions for activating and deactivating the feeders and wherein there is at least one programmed function to control a feed initiation and a feed rate for each treatment product through its feeder; 
 activating each feeder according to the programmed function associated with its treatment product to deliver an amount of each treatment product to the water system to achieve a desired initial concentration level for each treatment product in the water system; 
 wherein there is a set of matching visual indicators associated with each container, the visual indicators of each set being disposed on or near two or more of the container, its feeder, or at least one of the corresponding connection components to allow connection of each container with the correct feeder associated with the programmed function for the treatment product in the container; and 
 wherein each treatment product is useful alone or in combination with another treatment product for treating one or more of corrosion, white rust, scale, or biological contamination in the water system. 
 
     
     
       2. The method according to  claim 1  further comprising measuring a first parameter of the water using a first of the one or more sensors and verifying that at least one of the treatment products was fed to the water system in accordance with the programmed function for that treatment product based on the data or signal from the first sensor. 
     
     
       3. The method according to  claim 2  wherein the feeders are activated separately so that no treatment product from one feeder is fed into the water system simultaneously with a treatment product from another feeder. 
     
     
       4. The method according to  claim 2  wherein the measured first parameter is conductivity. 
     
     
       5. The method according to  claim 2  further comprising comparing the data or signal received related to the first parameter to pre-programmed data to determine whether the amount of treatment product fed into the water system is in accordance with the programmed function associated with that treatment product. 
     
     
       6. The method according to  claim 5  further comprising sending an alert message or activating an alarm when the comparison indicates that treatment product has not been fed into the water system according to the programmed function associated with the treatment product. 
     
     
       7. The method according to  claim 2  further comprising sending an alert message or activating an alarm when the verifying step indicates that at least one of the treatment products has not been fed into the water system. 
     
     
       8. The method according to  claim 2  further comprising measuring a second parameter of the water using a second of the one or more sensors, wherein the second sensor is disposed upstream of the feeders, sending data or a signal from the second sensor to the controller, and utilizing the data or signal from the second sensor as an input in at least one of the programmed functions;
 wherein the second sensor is inline fluorimeter, a pH meter, a conductivity meter, a flow meter, a flow switch, temperature sensor, an ORP sensor, or a sensor to monitor oxidant level: and 
 wherein the first sensor is disposed downstream of the feeders. 
 
     
     
       9. The method according to  claim 2  wherein the measured first parameter is a concentration of a first treatment product in the water system and wherein at least one of the programmed functions is a calculation of feeder activation time for a second treatment product based on a desired concentration level for the second treatment product in the water system, the measured concentration level for the first treatment product in the water system, and actual feeder activation time for the first treatment product to achieve that measured concentration level. 
     
     
       10. A method of controlling treatment of a water system comprising water, the method comprising the steps of:
 providing a first container containing an initial volume of a first treatment product; 
 providing a second container containing an initial volume of a second treatment product; 
 optionally providing one or more additional containers, each containing an initial volume of one of a plurality of additional treatment products; 
 wherein each container is connectable to a feeder using one or more connection components to feed the treatment product from that container to the water system; 
 providing a controller connected to the feeders, the controller having one or more programmed functions to control a feed initiation and a feed rate for each treatment product through its feeder; 
 activating each feeder according to the programmed function associated with its treatment product to deliver an amount of each treatment product to the water system to achieve a desired initial concentration level for each treatment product in the water system; and 
 tracking a total feed amount for each treatment product based on the feeder activation time and feed rate, comparing the initial volume of each treatment product in its container to its respective total feed amount to determine a remaining volume for each treatment product, and sending an alert or activating an alarm when the remaining volume for any treatment product is below a first predetermined threshold; and 
 wherein each treatment product is useful alone or in combination with another treatment product for treating one or more of corrosion, white rust, scale, or biological contamination in the water system; 
 wherein the first treatment product comprises an amino-acid based polymer (AAP), the second treatment product comprises a phosphonic acid other than hydroxyphosphonoacetic acid (HPA), and a third treatment product comprises HPA to treat corrosion, white rust, scale, or a combination thereof in the water system; and 
 wherein the one or more programmed functions control the feed rates of the AAP, phosphonic acid or its water soluble salt, and HPA to provide active initial concentrations in the water system and wherein the active initial concentrations in the water system are (1) at least 2 ppm AAP, at least 2 ppm HPA, and at least 1.5 ppm of the phosphonic acid other than HPA when it is desired to treat scale; or (2) at least 3 ppm AAP, at least 3 ppm HPA, and at least 2 ppm of the phosphonic acid other than HPA when it is desired to treat corrosion; or (3) at least 3 ppm AAP and at least 2 ppm of the phosphoric acid other than HPA when it is desired to treat white rust; and 
 wherein the AAP includes water soluble salts thereof, the phosphonic acid includes water soluble salts thereof, and the optional HPA includes water soluble salts thereof. 
 
     
     
       11. The method according to  claim 10  further comprising tracking the number of containers of each treatment product used or replaced and comparing an initial inventory amount of containers of that treatment product to its respective number of containers used or replaced to determine a remaining number of containers of that treatment product in inventory, and sending an alert or automatically ordering replacement inventory when the remaining number of containers for any treatment product is below a second predetermined threshold. 
     
     
       12. The method according to  claim 1  wherein each treatment product is in a concentrated liquid form and is for treating a single water system issue, and wherein at least one of the treatment products is in a non-hazardous form. 
     
     
       13. The method according to  claim 1  wherein each treatment product comprises only one active ingredient for treating the water and each treatment product is in a concentrated liquid form, and wherein at least one of the treatment products is in a non-hazardous form. 
     
     
       14. The method according to  claim 1  wherein a first treatment product comprises a single active ingredient and a second treatment product comprises a single active ingredient that is different from the first treatment product, and wherein at least one of the first or second treatment products is in neutralized form. 
     
     
       15. The method according to  claim 1  wherein each treatment product comprises a different active ingredient. 
     
     
       16. The method according to  claim 1  wherein a first treatment product comprises an amino-acid based polymer (AAP), a second treatment product comprises a phosphonic acid other than hydroxyphosphonoacetic acid (HPA), and an optional third treatment product comprises HPA to treat corrosion, white rust, scale, or a combination thereof in the water system;
 wherein the one or more programmed functions control the feed rates of the AAP, phosphonic acid, and optional HPA to provide active initial concentrations in the water system and wherein the active initial concentrations in the water system are (1) at least 2 ppm AAP, at least 2 ppm HPA, and at least 1.5 ppm of the phosphonic acid other than HPA when it is desired to treat scale; or (2) at least 3 ppm AAP, at least 3 ppm HPA, at least 2 ppm of the phosphonic acid other than HPA when it is desired to treat corrosion; or (3) at least 3 ppm AAP, optionally at least 3 ppm HPA, and at least 2 ppm of the phosphonic acid other than HPA when it is desired to treat white rust; and 
 wherein the AAP includes water soluble salts thereof, the phosphonic acid includes water soluble salts thereof, and the optional HPA includes water soluble salts thereof. 
 
     
     
       17. The method according to  claim 16  wherein the active initial concentrations in the water system are (1) between 2-50 ppm AAP, between 2-50 ppm HPA, and between 1.5-20 ppm of the phosphonic acid other than HPA when it is desired to treat scale; or (2) between 3-50 ppm AAP, between 3-50 ppm HPA, and between 2-20 ppm of the phosphonic acid other than HPA when it is desired to treat corrosion; or (3) between 2-50 ppm AAP, optionally between 3-50 ppm HPA, and between 2-20 ppm of the phosphonic acid other than HPA when it is desired to treat white rust. 
     
     
       18. The method according to  claim 16  wherein the active initial concentrations in the water system are (1) between 3-30 ppm AAP, between 2-20 ppm HPA, and between 1.5-10 ppm of the phosphonic acid other than HPA when it is desired to treat scale; or (2) between 5-30 ppm AAP, between 3-20 ppm HPA, and between 2-10 ppm of the phosphonic acid other than HPA when it is desired to treat corrosion; or (3) between 5-30 ppm AAP, between 3-20 ppm HPA, and between 2-10 ppm of the phosphonic acid other than HPA when it is desired to treat white rust. 
     
     
       19. The method according to  claim 16  wherein the one or more programmed functions also controls the activation time so that the AAP, phosphonic acid other than HPA, and optional HPA are fed into the water system substantially simultaneously or in substantially immediate sequential succession. 
     
     
       20. The method according to  claim 16  wherein the fourth treatment product comprises a biocide and wherein another programmed function controls the activation time for feeding the biocide so that it is fed substantially simultaneously or in substantially immediate sequential succession to one or more of the AAP, phosphonic acid other than HPA, and optional HPA. 
     
     
       21. The method according to  claim 1  wherein a first treatment product comprises a single active ingredient and a second treatment product comprises a single active ingredient different from the first treatment product. 
     
     
       22. The method according to  claim 1  wherein the feed rate for at least one treatment product is calculated by the controller based on duration of time a valve connected to the container for that treatment product is opened, duration of time a pump for the feeder for that treatment product is on, a flow meter reading, or a combination thereof. 
     
     
       23. The method according to  claim 2  wherein the first sensor is disposed downstream of the feeders and further comprising comparing the data or signal received from the first sensor to pre-programmed data or recorded measurements to determine whether a selected treatment product has been fed into the water system in accordance with the programmed function associated with that treatment product;
 sending an alert message or activating an alarm when the comparison indicates that treatment product has not been fed into the water system in accordance with the programmed function associated with that treatment product; 
 measuring a second parameter of the water upstream of the feeders using a second of the one or more sensors; 
 sending data or a signal from the second sensor to the controller; 
 utilizing the data or signal from the second sensor as an input in at least one of the programmed functions; and 
 wherein the second sensor is inline fluorimeter, a pH meter, a conductivity meter, a flow meter, a flow switch, temperature sensor, an ORP sensor, or a sensor to monitor oxidant level. 
 
     
     
       24. The method according to  claim 23  wherein the feed rate for one or more of the treatment products is adjusted based on the data or signal from the second sensor. 
     
     
       25. The method according to  claim 23  wherein the feed rate for the selected treatment product is adjusted based on the comparing step. 
     
     
       26. The method according to  claim 1  wherein at least one of the programmed functions is based on a combination of (1) a timer and (2) the data or signal from a first of the one or more sensors located downstream of the feeders or data or a signal from a second of the one or more sensors located upstream of the feeders or both. 
     
     
       27. The method according to  claim 26  wherein a first programmed function for a first treatment product is based on the timer and on the data or the signal from the second sensor; and
 wherein the second sensor is (1) a water meter on a bleed line or make-up water line for the water system or (2) a fluorimeter. 
 
     
     
       28. The method according to  claim 27  wherein the first programmed function determines a first feed time for the first treatment product and wherein a second programmed function for a second treatment product determines a second feed time for the second treatment product based on a ratio of the first feed time and specific gravity values for the first and second treatment products. 
     
     
       29. The method according to  claim 1  wherein the set of matching visual indicators associated with one container is different from the set of matching visual indicators associated with each other container. 
     
     
       30. The method according to  claim 1  wherein the treatments products are all in non-hazardous form. 
     
     
       31. The method according to  claim 1  wherein the treatment products are all in neutralized form. 
     
     
       32. The method according to  claim 11  wherein there is a set of matching visual indicators associated with each container, the visual indicators of each set being disposed on or near two or more of the container, its feeder, or at least one of the corresponding connection components to allow connection of each container with the correct feeder to receive signals from the controller associated with the programmed function for the treatment product in the corresponding container; and
 wherein the set of matching visual indicators for associated with each container is different from the set of matching visual indicators of each other container. 
 
     
     
       33. The method according to  claim 11  wherein the treatments products are all in non-hazardous form. 
     
     
       34. The method according to  claim 11  wherein the treatment products are all in neutralized form. 
     
     
       35. The method according to  claim 10  wherein the active initial concentrations in the water system are (1) between 3-30 ppm AAP, between 2-20 ppm HPA, and between 1.5-10 ppm of the phosphonic acid other than HPA when it is desired to treat scale; or (2) between 5-30 ppm AAP, between 3-20 ppm HPA, and between 2-10 ppm of the phosphonic acid other than HPA when it is desired to treat corrosion; or (3) between 5-30 ppm AAP, optionally between 3-20 ppm HPA, and between 2-10 ppm of the phosphonic acid other than HPA when it is desired to treat white rust; and
 wherein the one or more programmed functions also controls the activation time so that the AAP, phosphonic acid other than HPA, and optional HPA are fed into the water system substantially simultaneously or in substantially immediate sequential succession. 
 
     
     
       36. The method according to  claim 10  wherein the feed rate for at least one treatment product is calculated by the controller based on duration of time a valve connected to the container for that treatment product is opened, duration of time a pump for the feeder for that treatment product is on, a flow meter reading, or a combination thereof. 
     
     
       37. The method according to  claim 36  wherein the feed initiation comprises opening a valve, activating a pump, or a combination thereof. 
     
     
       38. The method according to  claim 1  wherein the feed initiation comprises opening a valve, activating a pump, or a combination thereof. 
     
     
       39. The method according to  claim 30  wherein the treatment products comprise at least one of the following: a phosphonate, a triazole comprising a glycol solution, butyl benzyl triazole, and chlorotriazole. 
     
     
       40. The method according to  claim 31  wherein the treatment products comprise at least one of the following: a phosphonate, a triazole comprising a glycol solution, butyl benzyl triazole, and chlorotriazole. 
     
     
       41. The method according to  claim 33  wherein the treatment products comprise at least one of the following: a phosphonate, a triazole comprising a glycol solution, butyl benzyl triazole, and chlorotriazole. 
     
     
       42. The method according to  claim 34  wherein the treatment products comprise at least one of the following: a phosphonate, a triazole comprising a glycol solution, butyl benzyl triazole, and chlorotriazole. 
     
     
       43. The method according to  claim 1  wherein each set of matching visual indicators comprises a color or a shape or a combination thereof. 
     
     
       44. The method according to  claim 29  wherein each set of matching visual indicators comprises a color or a shape or a combination thereof. 
     
     
       45. The method according to  claim 32  wherein each set of matching visual indicators comprises a color or a shape or a combination thereof. 
     
     
       46. The method according to  claim 1  wherein each treatment product is in a concentrated liquid form and at least one of the plurality of treatment products comprises (1) a polymer at a pH of 2.5 to 11, (2) a phosphonate at a pH of 2.5 to 11, or (3) a triazole in a glycol solution. 
     
     
       47. The method of  claim 1  wherein at least one of the plurality of treatment products comprises a triazole in a 25-50% propylene glycol solution.